Filtered electrical connector

ABSTRACT

An electrical filter connector terminal for being received, at least partially, in a ferrite hood. The terminal including a first connection section; a second female connection section; and a positioning section located between the first and second connection sections. The positioning section is aligned in a column with the second female connection section. The positioning section comprises an outer perimeter which is at least partially larger than an outer perimeter of the second female connection section. A first edge of the positioning section can contact a rear edge of a ferrite hood positioned onto the second female connection section. At least a portion of the outer perimeter of, the positioning section can contact an interior wall of a contact receiving hole of a connector housing for aligning the second female connection section in the contact receiving hole.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to electrical connectors and, moreparticularly, to filtered electrical connectors having ferrite members.

[0003] 2. Brief Description of Prior Developments

[0004] U.S. Pat. No. 5,489,220 discloses a filter connector with aferrite barrel for two electrical contacts. U.S. Pat. No. 5,213,522discloses a filtered connector with a multi-piece ferrite block. Aproblem with these types of ferrite blocks is that they must be made ofelectrically non-conductive ferrite oxide to prevent short-circuiting ofthe contacts and, therefore, cannot filter lower frequencies (about 1≦50MHz) without increasing length of the ferrite block and therebyincreasing the size of the connector. For a filtered connector intendedto be used in a small space, such as an air bag connector, increasingthe size of the connector is not desired. If an electrically conductiveferrite oxide material needed to be used for lower frequencyattenuation, such as about 1-150 MHz, electrical insulators would needto be added between the contacts and the ferrite block.

[0005] U.S. Pat. No. 6,152,775, which is hereby incorporated byreference in its entirety, discloses a filtered electrical connectorwith multiple ferrite members. In the embodiment shown in FIG. 4, thecontact has a stop surface for contacting a rear end of the ferritehood. The connector overcomes the problems noted above with regard toU.S. Pat. Nos. 5,489,220 and 5,213,522, but centering of the femalecontact section in the housing is controlled by the ferrite hood; whichis not a precise positioning system. There is a desire to provide aconnector which comprises a ferrite hood over a female connectionsection of a contact, but which has a more accurate and repeatablecontact positioning system.

[0006] In one type of conventional right-angle air bag filteredelectrical connector, there is a 90° bend or transition in the contactbetween the barrel of the contact and the lead portion of the contact.The transition has a cross-sectional curved shape. The positioning stopof the ferrite tube on the contact was the bottom surface of the leadportion. Thus, the compound curvature at the bent transition was locatedinside the ferrite tube. This widened, compound curved transitionrequired that the interior aperture of the ferrite tube be slightlylarger than the barrel section of the contact. This was because aclearance was needed. The material of the ferrite tube is relativelyfragile compared to the metal contact. If the clearance was not providedthe contact could damage the ferrite by causing it to crack. Thisclearance caused a floating problem of the contact relative with theferrite tube. Hence, this caused an alignment problem when attempting toconnect the connector to a mating connector. Misalignment could causedamage to the contacts. The present invention helps to reduce damage tothe connector by reducing misalignment problems. There is a desire toprovide better engagement and alignment than prior art air bagconnectors. There is also a desire to remove the tolerances factor ofthe ferrite hood from the alignment and engagement precision of theconnector with a mating connector.

SUMMARY OF THE INVENTION

[0007] In accordance with one aspect of the present invention, anelectrical filter connector terminal is provided for being received, atleast partially, in a ferrite hood. The terminal including a firstconnection section; a second female connection section; and apositioning section located between the first and second connectionsections. The positioning section is aligned in a column with the secondfemale connection section. The positioning section comprises an outerperimeter which is at least partially larger than an outer perimeter ofthe second female connection section. A first edge of the positioningsection can contact a rear edge of a ferrite hood positioned onto thesecond female connection section. At least a portion of the outerperimeter of the positioning section can contact an interior wall of acontact receiving hole of a connector housing for aligning the secondfemale connection section in the contact receiving hole.

[0008] In accordance with another aspect of the present invention, anelectrical filter connector assembly is provided comprising a housing,electrical contact terminals, and at least one ferrite hood. The housingis adapted to be plugged into a socket of a gas generator. The housingcomprises at least one contact receiving hole. The electrical contactterminals have a wire connection section, a female connection section,and a terminal positioning section. The terminals are located in the atleast one contact receiving hole. The at least one ferrite hood ismounted on the female connection sections of the terminals. The terminalpositioning sections of the terminals contact the housing in the atleast one contact receiving hole to align the female connection sectionsof the terminals relative to the at least one contact receiving hole.

[0009] In accordance with another aspect of the present invention, anelectrical filter connector assembly is provided comprising a housing,electrical contact terminals, and at least one ferrite hood. The housingis adapted to be plugged into a socket of a gas generator. The housingcomprises at least one contact receiving hole. The electrical contactterminals have a wire connection section, a female connection section,and a terminal positioning section. The terminals are located in the atleast one contact receiving hole. The at least one ferrite hood ismounted on the female connection sections of the terminals. The terminalpositioning sections of the terminals have a general tubular shape. Thegeneral tubular shapes are each aligned behind one of the femaleconnection sections and have an edge adapted to contact a rear end ofthe at least one ferrite hood.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The foregoing aspects and other features of the present inventionare explained in the following description, taken in connection with theaccompanying drawings, wherein:

[0011]FIG. 1 is a perspective view of an electrical connectorincorporating features of the present invention attached to an air baggas generator;

[0012]FIG. 2 is an exploded perspective view of the electrical connectorshown in FIG. 1;

[0013]FIG. 3 is a cross-sectional view of the electrical connector shownin FIG. 1;

[0014]FIG. 4 is an exploded perspective view of one of the electricalcontact terminals and ferrite hoods of the connector shown in FIGS. 2-3;and

[0015]FIG. 5 is a perspective view of the electrical contact terminaland ferrite hood shown in FIG. 4, with a cutaway section of the ferritehood and a cut-away section of a portion of one of the cantilevered armsof the positioning section of the terminal, which are shown in anassembled position.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0016] Referring to FIG. 1, there is shown a perspective view of anelectrical connector 10, incorporating features of the presentinvention, shown attached to an air bag gas generator 12. In alternateembodiments, the connector 10 could be attached to any suitable type ofgas generator or, to any other type of electrical or electroniccomponent. Although the present invention will be described withreference to the exemplary embodiment shown in the drawings, it shouldbe understood that the present invention can be embodied in manyalternate forms of embodiments. In addition, any suitable size, shape ortype of elements or materials could be used.

[0017] The connector 10, in this embodiment, is for use in connectingelectrical conductors 14, 15 with the air bag gas generator 12.Referring also to FIGS. 2 and 3, the connector 10 generally comprises ahousing 16, electrical contact terminals 18 and ferrite hoods 20. Thehousing 16 comprises a first housing piece 22 and a second housing piece24. The two housing pieces are preferably comprised of molded plastic orpolymer material. However, in alternate embodiments, any suitablematerial(s) could be used. In an alternate embodiment, the housing couldbe comprised of more or less than two housing pieces.

[0018] The first housing piece 22 includes two cantilevered fingeractuatable deflectable latches 26, two separate receiving areas 28, andtwo holes 30 through a bottom face 32 of the housing into the receivingareas 28. However, in alternate embodiments, the latches 26 might not beprovided. Alternatively, any suitable type of latching system could beprovided. The housing 16, at the bottom of the front section 34, isadapted to be plugged into a socket 36 of the gas generator 12. Thelatches 26 are adapted to latch with latch surfaces in the socket 36.optionally, additional connector position assurance means (not shown)can be provided to prevent the connector 10 from accidentally beingdisengaged from the gas generator 12. The second housing piece 24 ispreferably snap lock mounted onto the first housing piece 22 after thecontacts 18 and ferrite hoods 20 are located in the receiving areas 28.However, in alternate embodiments, any suitable type of connection couldbe provided. In addition, in alternate embodiments, other types ofhousings or housing components could be provided.

[0019] Referring also to FIGS. 4 and 5, the electrical contact terminals18 each comprise a first connection section 38, a second femaleconnection section 39, a positioning section 40. However, in alternateembodiments, the terminals 18 could comprise additional sections orsections which are shaped differently from the shapes of shown in thedrawings. Preferably, the contact terminals 18 are comprised of stampedand formed sheet metal. However, in alternate embodiments, the contactterminals could be comprised of any suitable material(s) and/or could beformed by any suitable contact manufacturing process.

[0020] The first connection section 38 is provided for forming a leadsection for the contact terminal 18. The first connection section 38 canbe crimped onto one of the electrical conductors 14, 15 for connectingthe electrical conductors 14, 15 to the contact terminal 18. However, inalternate embodiments, the first connection section 38 could have anysuitable shape. The conductors 14, 15 could be crimped, soldered orwelded to the first connection section 38. In the embodiment shown, thefirst connection section 38 is angled about 90° relative to the secondconnection section 39. However, the lead section could be straight foran in-line connector.

[0021] The positioning section 40 is located between the firstconnection section 38 and the second connection section 39. In theembodiment shown, the positioning section 40 generally comprises a mainshaft section 44 and two cantilevered arms 46, 48. In an alternateembodiment, the positioning section could comprise additional oralternative sections. For example, the positioning section 40 couldcomprise more or less than two cantilevered arms. As another example,the cantilevered arm(s) could be cantilevered in a downward directionrather than a lateral direction from the main shaft section.

[0022] The main shaft section 44 connects the first connection section38 to the second connection section 39. The two cantilevered arms 46, 48extend from opposite sides of the main shaft section 44. In theembodiment shown, the two cantilevered arms 46, 48 are substantiallymirror images of each other. However, in alternate embodiments, the twocantilevered arms could comprise different sizes and shapes. Eachcantilevered arm comprises a general curved shape. The cantilevered arms46, 48 extend outwardly from the main shaft section 44 and curvedinwardly towards each other. This forms the positioning section 40 witha general tubular shape. However, in alternate embodiments, thepositioning section 40 could comprise any suitable type of shape.

[0023] The positioning section 40 is sized and shaped to be received inthe upper part of one of the receiving areas 28. The outer surfaces ofthe cantilevered arms 46, 48 make a direct physical contact with theinner walls of the first housing piece 22 in the upper part of thereceiving area 28. In a preferred embodiment, the positioning section 40has its outer surfaces of the cantilevered arms 46, 48 make a matingfriction fit engagement with the inner walls of the receiving area 28.If desired, when the cantilevered arms 46, 48 are inserted into thereceiving area 28, they can resiliently deflect inward to form a pressfit mating of the positioning section 40 with the first housing piece22.

[0024] The cantilevered arms 46, 48 have a height which allows thepositioning section 40 to center the positioning section 40 and secondconnection section 39 in the receiving area 28. The cantilevered arms46, 48 form an outer perimeter which is larger than the outer perimeterof the second connection section 39. The cantilevered arms 46, 48 formcontact surfaces 54 on their bottom edges. The contact surfaces 54 arelocated laterally outward past the outer sides of the second connectionsection 39.

[0025] In the embodiment shown, the second female connection section 39.generally comprises two spring contact arms 42. However, in alternateembodiments, the second female connection section could comprise morethan two spring contact arms or, alternatively, could comprise anysuitable type of female shaped connection section. The two springcontact arms 42 extend in a general cantilever fashion from the mainshaft section 44 of the positioning section 40. In the embodiment shown,each spring contact arms 42 comprises a general curved cross-section andare substantially mirror images of each other. Thus, the secondconnection section 39 forms a general column shape. However, inalternate embodiments, the contact arms could have different shapesand/or could be different from each other.

[0026] In the embodiment shown, the general tubular shape of thepositioning section 40 is coaxially aligned with the center axis of thesecond connection section 39. However, in alternate embodiments, thepositioning section and the second connection section need not becoaxially aligned. The two spring contact arms 42 taper towards eachother towards their distal ends 56. The distal ends 56 flair outward toform a male contact entrance area 58. However, as noted above, inalternate embodiments the spring contact arms could comprise anysuitable type of shape.

[0027] In the embodiment shown, the second connection section 39 has alonger length than the ferrite hood 20. However, in an alternateembodiment, the second connection section might not be longer than theferrite hood. The second connection section 39 is sized and shaped to beinserted into the ferrite hood 20. In a preferred embodiment, the topportion of the second connection section 39 makes a friction fit withthe inside wall of the ferrite hood 20. When the ferrite hood 20 islocated on the contact terminal 18, the distal ends 56 of the springcontact arms 42 extend outward past the bottom end of the ferrite hood20.

[0028] The ferrite hoods 20 are provided as two separate members; onefor each contact terminal 18. However, in an alternate embodiment, theconnector might only comprise one ferrite hood. In a preferredembodiment the ferrite hoods 20 have tube shapes and are comprised ofthe same material, such as electrically conductive ferrite oxide.However, the hoods could have different shapes, could be comprised ofelectrically non-conductive ferrite oxide, and/or the hoods could bemade of differing materials; such as one hood being made of electricallyconductive ferrite oxide and the other hood being made of electricallynon-conductive ferrite oxide.

[0029] In the embodiment shown, the two receiving areas 28 are separatedby a wall 50 of the housing 16. The receiving areas 28 have shelves 52above the holes 30 that allow the bottom edges of the ferrite hoods 20to be positioned against. The ferrite hoods 20 are matingly received inthe separate receiving areas 28. In an alternate embodiment, the firsthousing piece 22 might not comprise the wall 50, and the two ferritehoods 20 could physically contact each other.

[0030] The socket 36 of the gas generator 12 shown in FIG. 1 has twomale pin contacts (not shown) at a fixed spacing relative to each otherthat are received in the two female connection sections 39 through theholes 30 in the housing 12. Thus, the contact terminals 18 are able toelectrically connect the male pin contacts (not shown) to the conductors14, 15.

[0031] When the contact terminals 18 are connected to the conductors 14,15, the hoods 20 placed on the contact terminals 18, and the hoods andterminals placed in the first housing piece 22, the second housing piece24 is then snap lock mounted onto the first housing piece 22 to capturethe terminals and hoods in place at a fixed relationship to each other.The first and second housing pieces 22, 24 also provide strain relieffor the, conductors 14, 15 at the rear section 35. In an alternateembodiment the strain relief might not be provided, or could be providedby an over-molded third housing piece (not shown) or any other suitablemeans.

[0032] By providing each terminal 18 with its own separate and spacedferrite hood 20, the hoods 20 can now be comprised of electricallyconductor ferrite oxide, such that certain frequencies can be attenuatedwhich otherwise could not be attenuated with electrically non-conductiveferrite oxide. The shapes of the hoods 20 are optimized for maximumefficiency such that excess ferrite oxide material is not used. Comparedto the ferrite block in U.S. Pat. No. 5,489,220, about 75 percent lessferrite material can be used. This can obviously reduce the size of theoverall connector. Thus, cost and weight and size of the connector canbe minimized.

[0033] The embodiment shown can allow two different ferrite oxidematerials to be used in the same connector, such is one for highfrequency attenuation and one for low frequency attenuation for a betteror wider range of filtering. Even though the ferrite hoods 20 can bemade of electrically conductive material, they can still be mounteddirectly on the terminals 18 without use of an insulator between the twoferrite members because the two ferrite hoods 20 are electricallyseparated from each other. When attempting to reduce the size of afilter connector using a ferrite block by making the ferrite blocksmaller more filtering problems would be expected to be encountered. Theembodiment shown can provide a means to reduce the size of the connectorwhile maintaining good filtering by providing separate hoods for eachcontact and by optimizing the length and width of each hood 20 for thebest filtering without unnecessary ferrite oxide material.

[0034] A direct mechanical connection between the terminals 18 and hoods20 also makes assembly easier and less expensive regardless of whetherthe hoods 20 are comprised of electrically conductive or non-conductivematerial. The present invention can also be combined with a coil filterin the connector if desired, and is preferably used with a shorting barin the socket 36.

[0035] Preferably, the hoods 20 are comprised of metal powder which ispressed into a mold and sintered into shape.

[0036] Alternative manufacturing, such as extrusion could also be used.If the housing allows for servicing by opening or removing the housing,the terminals can be reused by merely disconnecting the hoods 20 fromthe terminals 18 and attaching new ferrite hoods. Thus, the connector 10is serviceable after the gas generator 12 is used.

[0037] The female connection sections 39 are received inside respectiveones of the hoods 20. When the contact terminals 18 are inserted intothe hoods 20, a top surface 60 of the ferrite hood 20 contacts thecontact surfaces 54 of the cantilevered arms 46, 48 of the positioningsection 40. The positioning section 40 functions as a stop for locatingthe ferrite hood 20 at a predetermined longitudinally position on thesecond connection section 39. Thus, the positioning section 40 can beused to perform two different positioning or locating functions. Thepositioning section 40 can directly align the second connection section39 with the receiving area 28 of the housing 16. Thus, the embodimentdescribed above can provide to the feature of centering the terminalusing the plastic housing 16 rather than using the ferrite hood 20. Theplastic housing 16 can be molded with greater precision than the formingof the ferrite hood 20. Thus, manufacturing tolerances of the assemblycan be improved. In addition, the positioning section 40 canlongitudinally position the ferrite hood 20 at a predetermined axialposition relative to the second connection section 39.

[0038] It should be understood that the foregoing description is onlyillustrative of the invention. Various alternatives and modificationscan be devised by those skilled in the art without departing from theinvention. Accordingly, the present invention is intended to embrace allsuch alternatives, modifications and variances which fall within thescope of the appended claims.

What is claimed is:
 1. An electrical filter connector terminal for beingreceived, at least partially, in a ferrite hood, the terminalcomprising: a first connection section; a second female connectionsection; and a positioning section located between the first and secondconnection sections, wherein, the positioning section is aligned in acolumn with the second female connection section, and wherein thepositioning section comprises an outer perimeter which is at leastpartially larger than an outer perimeter of the second female connectionsection such that a first edge of the positioning section can contact arear edge of a ferrite hood positioned onto the second female connectionsection and, such that at least a portion of the outer perimeter of thepositioning section can contact an interior wall of a contact receivinghole of a connector housing for aligning the second female connectionsection in the contact receiving hole.
 2. An electrical filter connectorterminal as in claim 1 wherein the first connection section comprises awire connection section.
 3. An electrical filter connector terminal asin claim 1 wherein the first connection section is angled at a generalright angle relative to the second female connection section.
 4. Anelectrical filter connector terminal as in claim 1 wherein the terminalis comprised of a one-piece member formed from stamped and formed sheetmetal.
 5. An electrical filter connector terminal as in claim 1 whereinthe positioning section comprises a general tubular shape formed by atleast one cantilevered curved arm.
 6. An electrical filter connectorterminal as in claim 5 wherein the at least one cantilevered curved armcomprises two of the cantilevered curved arms which curve outward andthen inward towards each other.
 7. An electrical filter connectorterminal as in claim 1 wherein the second female connection sectioncomprises a general tubular shape formed by at least one cantileveredcurved arm.
 8. An electrical filter connector terminal as in claim 7wherein the at least one cantilevered curved arm comprises two of thecantilevered curved arms, the two cantilevered curved arms beingsubstantial mirror images of each other.
 9. An electrical filterconnector assembly comprising: a housing adapted to be plugged into asocket of a gas generator, the housing comprising at least one contactreceiving hole; a plurality of electrical contact terminals located inthe housing, the plurality of electrical contact terminals comprisingthe electrical filter connector terminal as in claim 1; and at least oneferrite hood mounted on the female connection section of the electricalfilter connector terminal.
 10. An electrical filter connector assemblycomprising: a housing adapted to be plugged into a socket of a gasgenerator, the housing comprising at least one contact receiving hole;electrical contact terminals having a wire connection section, a femaleconnection section, and a terminal positioning section, the terminalsbeing located in the at least one contact receiving hole; and at leastone ferrite hood mounted on the female connection sections of theterminals, wherein the terminal positioning sections of the terminalscontact the housing in the at least one contact receiving hole to alignthe female connection sections of the terminals relative to the at leastone contact receiving hole.
 11. An electrical filter connector assemblyas in claim 10 wherein the housing is comprised of a molded polymermaterial.
 12. An electrical filter connector assembly as in claim 10wherein the terminal positioning sections form a friction fit betweenthe terminals and the housing in the contact receiving holes.
 13. Anelectrical filter connector assembly as in claim 10 wherein the wireconnection section is angled at a general right angle relative to thefemale connection section.
 14. An electrical filter connector assemblyas in claim 10 wherein the terminals are each comprised of a one-piecemember formed from stamped and formed sheet metal.
 15. An electricalfilter connector assembly as in claim 10 wherein the positioningsections each comprise a general tubular shape formed by at least onecantilevered curved arm.
 16. An electrical filter connector assembly asin claim 15 wherein each terminal comprises two of the cantileveredcurved arms which curve outward and then inward towards each other. 17.An electrical filter connector assembly as in claim 10 wherein thesecond female connection sections each comprise a general tubular shapeformed by at least one cantilevered curved arm.
 18. An electrical filterconnector assembly as in claim 17 wherein each terminal comprises two ofthe cantilevered curved arms, the two cantilevered curved arms beingsubstantial mirror images of each other.
 19. An electrical filterconnector assembly comprising: a housing adapted to be plugged into asocket of a gas generator, the housing comprising at least one contactreceiving hole; electrical contact terminals having a wire connectionsection, a female connection section, and a terminal positioningsection, the terminals being located in the at least one contactreceiving hole; and at least one ferrite hood mounted on the femaleconnection sections of the terminals, wherein the terminal positioningsections of the terminals have a general tubular shape, and wherein thegeneral tubular shapes are each aligned behind one of the femaleconnection sections and have an edge adapted to contact a rear end ofthe at least one ferrite hood.
 20. An electrical filter connectorassembly as in claim 19 wherein the general tubular shape has an outerperimeter which is at least partially larger than an outer perimeter ofthe at least one ferrite hood, such that the outer perimeter of thegeneral tubular shape contacts an interior wall of the housing in thecontact receiving hole to align the female connection section in thecontact receiving hole.